Baseload LNG Production in Xin Jiang

Contents.
3 4 Introduction The basics
Design basis Basic data for the process design of the plant Feed gas composition Specification of the product LNG Process features Utilities Block diagramm of the Shan Shan LNG plant

Features I
Ambient conditions at the site Overall process and utility description Natural gas treatment Natural gas liquefaction Block diagram of the liquefaction

Features II
Refrigerant system Gas turbine LNG storage and loading system Block diagram of the LNG storage tank and loading system

11

Features III
Fuel system Hot oil unit Main cryogenic heat exchanger Project execution

Xiang Dong President Xin Jiang Guanghui Liquefied Natural Gas Development Co. Ltd. gh-LNG@163.com, 838202 Shan Shan, PRC Thilo Schiewe Sales Manager, Natural Gas Plants thilo.schiewe@linde-le.com, Linde AG, Engineering Division Dr.-Carl-von-Linde-Str. 6-14, 82049 Pullach, Germany Albert Meffert Project Manager a.meffert@tractebel.de, Tractebel Gas Engineering Mildred-Scheel-Str.1, 53175 Bonn, Germany Li Wei Bin LNG Chief Representative liweibin@ssec.com.cn, SSEC, SINOPEC Shanghai Engineering Co. Ltd., 769 Zhangyang Road, Pudong New Area, Shanghai, PRC

13 14

Project execution Closing remarks

Selected references

16

Contact

Introduction.
Baseload LNG production in Xin Jiang - a remote source of clean energy for gas consumers in China. In 2004 Xin Jiang Guanghui Liquefied Natural Gas Development Co. Ltd. established a unique LNG chain. The result is that gas, which until recently has been flared at the Tuha oilfields some 300 km south-west of Urumqi, can now be utilized as a clean primary energy source. This new LNG scheme is a feasible and workable alternative to existing peak shaving and conventional baseload plants. With a LNG production capacity of 0.4 MTPA (million tons per annum) the plant represents a new category of LNG plant types, with which a specific demand can be fulfilled.

The gas is treated and liquefied in an LNG plant near Shan Shan in the Xin Jiang Province of China. The plant is operated in baseload mode and employs intermediate storage of the LNG product in an insulated tank before it is loaded into LNG road tankers. These trucks then carry the LNG over long distances to satellite and car fuelling stations in various cities of China. After revaporization of the LNG at these stations the natural gas is finally distributed to a variety of industrial and private consumers.

As LNG is considered the most environmentally friendly hydrocarbon fuel, it is expected that this domestic natural gas initiative through LNG creates new gas markets and provides a great improvement to the tight energy supply situation in China. This paper describes the Shan Shan LNG facilities from gas treatment, liquefaction with a single mixed refrigerant cycle in coilwound heat exchangers, through storage, to unloading and to the distribution of the LNG to various cities in China.

The Basics.
Design basis The baseload LNG plant is designed for the production of LNG equivalent to 1,500,000 Nm3/d. The plant consists of natural gas treatment, gas liquefaction, LNG storage tank and LNG distribution systems. The liquefaction process is based on a highly efficient single mixed refrigerant cycle. Basic data for the process design of the plant The design of the LNG plant for the Xin Jiang project is based on state-of-the-art natural gas liquefaction technology. The LNG production capacity of the plant is equivalent to 1,500,000 Nm3/d with an expected on-stream time of 330 days per year. Design hourly liquefaction capacity is 54 t/h. Storage capacity is 30,000 m3 of LNG, which is the equivalent of 12 days production. The capacity of the LNG send-out and distribution system meets the requirement of loading the 100 trucks and movable containers within 16 hours. Approx. 30 % of the LNG product is loaded in trucks and 70 % in movable containers. Feed gas composition Composition (mole %): Nitrogen 3.81 Methane 81.02 Ethane 9.99 Propane 4.10 Butanes 0.93 Pentanes 0.05 C6+ < 0.0021 In addition, CO2 as well as traces of H2S and sulfur are present in the feed gas. The feed gas operating pressure ranges from about 0.6 MPag to 1.1 MPag. The design pressure is 0.7 MPag. The feed gas operating temperature can range from -15C to 40C. The design temperature is 28C. Specification of the product LNG Composition (mole %): Nitrogen 0.8 (max 1.0) Methane 82.4 Ethane 11.1 Propane 4.6 Others 1.1 Pressure and temperature at LNG tank: 0.01MPag, 163C. The design LNG has a density of about 490 kg/m3 in the LNG tank. Process features The main process and utility units are illustrated in the block diagram in Fig1. The mixed refrigerant cycle liquefaction process requires the components nitrogen, methane, ethylene, propane and pentane. Refrigerant nitrogen and purge nitrogen are identical and case both generated in a nitrogen package. Utilities Make-up water for the following are provided from outside the plant: closed cooling water cycle, machinery cooling and demineralized water as make-up water for the MEA in the CO wash unit. A mixture of compressed LNG tank return gas and feed gas is used as normal fuel gas; start-up fuel gas is feed gas. A closed hot oil cycle is used as heating medium. A MEA (monoethanolamine)-water solution is used as solvent for the CO2 wash unit.

The liquefaction process is based on a highly efficient single mixed refrigerant cycle,

Waste water

Sour gas

Exhaust gas
flue gas

Hot oil system

hot oil hot oil

hot oil

Waste heat recovery

Gas turbine

fuel gas

fuel gas

hot oil

hot oil

Solvent regeneration
solvent solvent lean rich

Refrigeration system
liquid refr. vap. refr.

Boil off gas (fuel gas) compression

Natural gas

Feed gas compression

NG

NG purification CO2 removal

purified NG

dry

NG purification NG dryer

NG liquefaction

LNG

LNG storage

LNG

LNG loading station container LNG loading station special cont. LNG loading station truck

LNG

LNG meters MCR make-up unit

LNG

Fire fighting

Utilities

Flare

LNG

LNG meters

Fig1: Block diagram of the Shan Shan LNG plant with process and utility units

which contains the components nitrogen, methane, ethylene, propane and pentane.

Features I
Ambient conditions at the site The average ambient temperatures ranges from 37.1C in the warmest month to -15.6C in the coldest month. The design temperature for gas turbine air inlet and for air-cooling is 30C. The average temperature in the hottest month is 37C, the extreme maximum temperature is 75C. The plant elevation above sea level is about 790 m. Overall process and utility description The production capacity of Shan Shan LNG lies between the two principle type of LNG plants: Baseload and peakshaving plants. LNG peakshaving or back-up plants with intermittent operation and production have capacities up to about 500,000 Nm3/d. LNG baseload plants with continuous operation and production have capacities between 5,000,000 Nm3/d and 17,000,000 Nm3/d. With 1,500,000 Nm3/d LNG production capacity the Shan Shan LNG plant is about three times larger than the largest existing peakshaving plants, but about three times smaller than existing baseload plants. The feed gas has a low pressure at battery limit, which is too low for an efficient liquefaction process. Therefore, the natural gas is compressed in three compressor stages. The natural gas is cooled, liquefied and subcooled in a coil-wound heat exchanger by a highly efficient single mixed refrigerant cycle. This cycle provides cold temperatures by JouleThomson expansion at three different pressure levels. The refrigerant cycle is recompressed in a threestage turbo-compressor, which is driven by a gas turbine. In order to enhance plant efficiency, the waste heat from the gas turbine is recovered by heating a hot oil cycle, which covers the heating requirements of the process plant. Natural gas treatment Natural gas (feed gas) has a low pressure at the battery limit. Solid and liquid particles are removed by the feed gas filter separator before it is compressed in a three stage feed gas compressor. After the first-stage of the feed gas compressor, the gas is cooled in an intercooler against ambient air to about 40C. Any water condensed in the intercooler is separated in the feed gas compressor interstage drum and is fed to the wash unit. After this first compression step the feed gas is further compressed in the next two compressor stages with inter- and after-cooling in air-coolers. The feed gas is routed to the wash unit for removal of CO2. The sweet feed gas leaving the CO2 wash column is then routed to the drier station. Natural gas liquefaction (Fig. 2) After the CO2 and H2O removal, the natural gas is routed to the cold part of the process, which contains three coil-wound heat exchangers integrated in one shell (rocket), as well as several separation vessels. The natural gas is first cooled in the feed gas precooler E1. Potential off-spec heavy hydrocarbons are separated in the feed gas heavy hydrocarbon separator D3, where only marginal liquids during design feed gas operation are expected. The gas is then condensed in feed gas liquefier E2 and subcooled in feed gas subcooler E3. The required subcooling temperature is maintained by adjusting the natural gas flow rate to the plant. Thus, a certain power output of the gas turbine govering the plant capacity. Cooling is provided by the mixed refrigerant cycle.

The Shan Shan LNG plant has a medium size production capacity,

LNG to storage tank

Cycle compressor coolers

E3 Subcooler

CT1 Gas turbine

E2 Liquefier

D3 Cold MCR separator

C1 Cycle compr.

D2 Cycle HP separator

D1 Cycle MP separator E1 Precooler Cycle compressor suction drums

D3 Feed gas HHC separator

Feed gas

Feed gas compression, CO2/H2O removal

Fig 2: Natural gas liquefaction process of the Shan Shan LNG plant

in between the two principle types of LNG plants which are currently in operation world-wide.

Features II
Refrigerant system The refrigerant gas stream is withdrawn from the shell side of precooling section E1 of the cryogenic coil-wound heat exchanger set. The refrigerant is slightly super-heated. The refrigerant is compressed in the first stage of the three-stage refrigerant cycle compressor. It is than cooled against air in the inter- and aftercooler resulting in partial condensation. The resulting liquid is separated in the cycle compressor discharge drum D1. The liquid from the discharge drum D1 is routed to the cryogenic heat exchanger E1, where it is subcooled and then used for the precooling of the natural gas after expansion in a Joule-Thomson valve. The cycle gas from the buffer drum D2 is cooled in E1 to the same temperature and partly condensed and fed to the cold refrigerant separator D3. The liquid from this separator is subcooled in the cryogenic heat exchanger section E2 to a low temperature so that it can be used as a refrigerant in E2 after expansion in a Joule-Thomson valve. The vapor from the cold refrigerant separator D3 is condensed in E2 and subcooled in the cryogenic heat exchanger section E3 to a sufficiently low temperature. This provides the final cold for the natural gas subcooling after throttling in a Joule-Thomson valve. After expansion to the lower pressure, the cycle gas streams are warmed up in the common shell side of the cryogenic coil-wound heat exchangers E3, E2 and E1 and return jointly to the suction side of the first stage of the refrigerant cycle compressor. Gas turbine Gas turbine GT1 is used as the primary driver for the cycle gas compressor C1. Design temperature for gas turbine rating is an ambient air temperature of 30C. The same design temperature applies for air-cooling. The compressed boil-off, flash and displacement gas from the LNG storage tank is used as regeneration gas and then as fuel gas for the gas turbine. LNG storage and loading system LNG from the liquefaction unit with the cryogenic heat exchanger set E1, E2 and E3 is sent to the storage tank via the tank filling line, Fig. 3. The 30,000 m3 LNG tank (Fig. 5) is a flat bottom, double wall, perlite insulated type installed in an endiked area. The tank will be filled continuously during operation of the liquefaction system at a filling rate of about 111 m3/h. A discontinuous send out of LNG product to the truck and container filling facilities is scheduled for 16 hours per day.

Fig 3: 30,000 m3 LNG storage tank

Fig. 4: LNG truck loading station

For send-out operation, two submerged in-tank pumps are installed. Each designed for 320 m3/h capacity, suitable for 100 % of send-out capacity. One pump is installed as a spare. The pumps are installed in pump columns inside the tank and equipped with foot valves. Each pump is equipped with a kickback line to the tank to control the minimum flow of the pump during the period when no filling operation takes place. The send out lines to the truck and container filling station are permanently filled with LNG. A small circulation flow keeps the system at cryogenic temperatures. The trucks are weighed prior to filling. Trucks are connected manually to the loading arm filling and vapor return lines. The initial LNG into the warm tanks truck evaporates The resulting vapor returns to the storage tank. After cooling the truck tank, the filling rate increases to the maximum filling rate. The flow meter stops the filling operation automatically via the automatic control valve at the loading station. The truck leaves the plant via the weighbridge after disconnection from the loading arm. Fig. 4 shows the LNG truck loading station with four trucks each with a storage capacity of 44 m3. The loading capacity of the

stations is sufficient to match the send out capacity by operationg 16 hours a day. The same operation applies to the container filling system. The only difference is that trucks are mobile by themselves and the container must be moved by gantry crane and trailers.

The container is fixed on rail-platform cars and transported as train of 40 to 70 cars in length. The filling time for one container or one truck is estimated to be about 1.2 hours including connection and disconnection time. The system capacity is designed to fill 100 trucks or containers within 16 hours. The filling system consists of six loading stations for containers and four loading stations for trucks.

Fig. 5: LNG storage tank and loading system of the Shan Shan LNG plant

LNG from liquefier

Vapor return container filling station Boil-off/flash/displacement gas to re-compression

Container and truck filling station L-421 A/B/C/D/E/F D-411 LNG storage tank L-431 L-441 A/B/C

P-411 LNG transfer pump

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Features III
Fuel system The net flash, boil-off and displacement gas coming from the LNG storage tank is compressed, cooled against ambient air and used as regeneration gas in the dehydration section before it is sent as fuel to the gas turbine, which drives the cycle compressor. To allow for pressure control of the fuel gas, an additional fuel stream is taken from the feed gas following the second stage of the feed gas compressor. Hot oil unit The hot oil system provides the process heat for the plant at two temperature levels. In order to keep constant flow rates in the system, two cycles are used: a medium temperature cycle and a high temperature cycle. The heat for both cycles is provided by a hot oil heater package, a waste heat recovery unit in the exhaust stack of the cycle gas turbine. The hot oil is heated to approx. 260C to supply heat for the regeneration gas heating. To allow for start-up during winter conditions, the system is heat traced.

Fig. 6: Three stage 43 m high coil-wound heat exhanger with separator in the steel frame

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Fig. 7: Precooling section of the coil-wound heat exchanger in the Linde workshop

Main cryogenic heat exchanger A special feature of the cryogenic section of the process plant is the coil-wound heat exchanger which is designed and built by Linde. The coil-wound heat exchanger The robust design of the coil-wound heat exchanger is ideally suited for the pre-cooling, liquefaction and sub-cooling processes. During these processes, the refrigerant and product streams reach temperatures as low as -160C. Fig. 7 shows the precooling section of the coilwound heat exchanger in the Linde workshop prior to transport. The outer dimensions (length x diameter) of the three coil-wound heat exchanger sections are: Precooler: 15 m x 3 m Liquefier: 17 m x 3 m Subcooler: 11 m x 2 m

All three heat exchanger sections were transported separately to the site. After concentric stacking and welding in a steel structure, the combined coil-wound heat exchangers have an overall height of 43 m. Fig. 6 (page 10) shows the cryogenic section with the coil-wound heat exchanger together with the separator in the permanent steel frame. In comparison to plate-fin heat exchangers, the coil-wound heat exchanger can with stand significant thermal shocks. Thermal shocks may occur during startup or shut-down or mal-operations.

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Project execution.
The execution of the Shan Shan project is an example for the excellent cooperation between the owner of the plant, the liquefaction and tank technology providers, and the local design institute. SPIDI in Shanghai, China was responsible for the entire plot plan of the plant and detail engineering with utilities. Tractebel Gas Engineering in Bonn, Germany was responsible for the design of the LNG storage tank and the loading facilities and the procurement of the relevant imported equipment and material as well as for the construction and commissioning supervision of the tank and loading units. The Engineering Division in Munich, Germany was responsible for the natural gas treatment and liquefaction process design and for the procurement of the imported process related equipment as well as for the supervision of plant construction and commissioning. Fig. 9 (page 13) shows a section of the Shan Shan LNG plant with the compressor shelter building, the gas turbine exhaust stack, the coil-wound heat exchanger in the rack, the LNG tank and the air coolers on the pipe rack. The plant was mechanically completed in 2004 followed by commissioning. The equipment and piping was arranged in such a way as to take into account the relevant safety regulations as well as short pipeline lengths. The required plant area is about 58 m x 130 m. The LNG storage tank is connected to the process plant by a pipe rack, which supports the product and the vapor return line. A large fleet of LNG trucks, Fig. 8, is now permanently transporting the LNG over long distances to the satellite stations in the vicinity of the consumers. Most of the LNG satellite stations are located in the more densely populated regions in the eastern provinces of China. An overview of the existing and planned LNG satellite stations is shown in Fig. 10 (page 13). As is evident from the table, the one way distances mostly exceed 3,000 km, some are even greater than 4,000 km. The Dehua satellite station, Fig. 11 (page 15), represents the longest distance from the Shan Shan LNG plant. This station comprises eight vertically installed cylindrical LNG storage tanks, each with a capacity of 150 m3. They are filled regularly by the LNG trucks. The LNG is vaporized by blocks of finned heat exchangers using natural convection of ambient air as heat source. Small LNG containers are often filled with LNG from these large satellite stations and transported to smaller satellite stations in order to a limited residential areas. One of the urgent needs for clean fuel comes from public busses. Therefore, one of the LNG satellite stations supplies the LNG directly to a city bus fleet.

Fig: 8: Part of the fleet of LNG trucks for the road transportation of the Shan Shan LNG

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Fig. 10: LNG transport in China from the Shan Shan LNG plant

Fig. 9: Section of the Shan Shan LNG plant with compressor shelter, gas turbine exhaust stack, coil-wound heat exchanger and LNG tank

Shan Shan LNG plant Station Linyi Rizhao Lianyungang Qingdao Weihai Jiangyan Qidong Tongxiang Yuyao Beijing Minqing Dehua Changde Changsha Zhuzhou Jiujiang Ji An Nanchang Guangzhou Jiangyang Longchuan Dongguan Urumqi Hami Distance 3,400 km 3,520 km 3,450 km 3,600 km 3,700 km 4,100 km 3,400 km 3,700 km 3,920 km 3,170 km 4,050 km 4,400 km 3,190 km 3,450 km 3,520 km 3,250 km 3,700 km 3,400 km 4,040 km 4,350 km 4,200 km 4,120 km 340 km 340 km

LNG satellite station

LNG satellite station

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Closing remarks.
Demand for natural gas in China is projected to increase drastically in the future. This Shan Shan LNG plant will open a new era in meeting the increasing demand. With the introduction of such LNG plants, combined with the respective transport infrastructure, natural gas markets can be dynamically developed in the future. It is evident that natural gas, as a cleaner fuel, will play an increasingly important role in the primary energy mix. The LNG from the Shan Shan LNG plant will contribute substantially to the economic development and growth in China. With the LNG from Shan Shan, a high degree of flexibility in the energy supply will be made available to the benefit of all natural gas consumers with fluctuating or peak demand profiles. The Shan Shan LNG plant provides a means to commercialize indigenous natural gas resources. This, in turn, supports the local economy and provides jobs. The Shan Shan LNG plant provide a rubber tyre pipeline in China. The transport of LNG via tanker trucks makes the distribution of natural gas to intermediate-sized consumers possibel. Some of the target regions have not yet been connected to major gas pipelines due to economic reasons, since the initial gas consumption rate would not justify such a large investment. Therefore, the LNG supply will initiate the penetration of these regional markets with environmentally friendly fuel. This LNG scheme is unique in the world with regard to plant type as well as plant and transport capacity. It can be considered as an a model for the commercialization of remote gas resources.

With the introduction of such LNG plant types combined with the respective transport infrastructure, natural gas markets can be dynamically introduced and developed.

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Fig 11: Dehua LNG satellite station

Selected references E. Berger, Engineering Division: Xiang Dong, Xinjiang Guanghui Industry and Commerce Group Co. Ltd. Jin Guo Qiang, Shanghai Pharmaceutical Industry Design Institute of SINOPEC (SPIDI) Natural gas liquefaction - technical and economic aspects First Indian LNG conference, Madras, India, 1996 LNG satellite stations in Europe LNG 10 conference in Kuala Lumpur, Malaysia, 1992

A. Meffert, Tractebel Gas Engineering, L. Atzinger, Engineering Division: LNG baseload plant in Xinjiang, China; commercialization of remote gas resources for an Eco-responsible Future World gas conference, Tokyo, 2003

W. Frg, W. Bach, R. Stockmann, Engineering Division, R.S. Heiersted, P. Paurola, A.O. Fredheim, Statoil: A new LNG baseload process and manu- facturing of the main heat exchangers LNG 12 conference, Perth, May 1998

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